D-436-26 - TE Connectivity Splice Cable Connection 10-12 AWG Crimp

D-436-26 – TE Connectivity Raychem MiniSeal® Environmental Crimp Splice

Available now on the Airparts.aero Marketplace.

Overview

The TE Connectivity D-436-26 is a military-specification, high-performance, environmentally sealed in-line crimp splice from the renowned Raychem MiniSeal® product line. This is a flight-critical component designed to create an exceptionally rugged, reliable, and waterproof connection for 10 to 12 AWG wires in the most demanding aerospace environments. The splice consists of a nickel-plated copper crimp barrel housed within a transparent, heat-shrinkable Polyvinylidene Fluoride (PVDF) sleeve. Integrated into the sleeve are two thermoplastic sealing rings.

When properly crimped and heated, the D-436-26 creates a multi-functional connection. The crimp provides a robust, low-resistance electrical and mechanical bond. The heat-shrinkable sleeve provides strain relief and abrasion resistance. Most critically, the thermoplastic rings melt and flow, creating a complete adhesive seal that encapsulates the connection, making it fully waterproof and impervious to a wide range of aerospace fluids. For any wiring application in a high-vibration, moisture-prone, or mission-critical area, the MiniSeal® splice is the definitive engineering solution.

Key Features

• Mil-Spec Certified: Manufactured and tested in strict accordance with SAE-AS81824/1 (formerly MIL-S-81824/1), guaranteeing performance, quality, and traceability.

• Complete Environmental Sealing: The thermoplastic sealing inserts and heat-shrinkable sleeve create a fully waterproof, immersion-resistant, and corrosion-proof seal.

• Transparent Sleeve for Inspection: The high-temperature PVDF sleeve is transparent, allowing for the visual inspection of the crimp quality and wire insertion after installation, a critical quality assurance feature.

• Superior Strain Relief: The tough, semi-rigid sleeve provides excellent support to the wire, protecting the crimp joint from fatigue failure due to vibration and mechanical stress.

• Color Coded for Wire Size: The Yellow color of the sealing rings provides a clear and unambiguous visual identification for its intended wire size (12-10 AWG).

• Wide Temperature Range: Engineered for reliable performance in temperatures ranging from -55°C to +150°C.

Technical Specifications

• Part Number / Specification: D-436-26

• Component Type: In-Line Crimp Splice, Environmentally Sealed

• OEM Manufacturer: TE Connectivity (Raychem)

• Wire Gauge Range (Color): 12 - 10 AWG (Yellow)

• Material (Crimp Barrel): Nickel-Plated Copper Alloy

• Material (Insulation Sleeve): Radiation-Crosslinked, Heat-Shrinkable Polyvinylidene Fluoride (PVDF), Transparent.

• Material (Sealing Rings): Thermoplastic Copolymer

• Maximum Operating Temperature: 150°C (302°F)

• Governing Specification: SAE-AS81824/1, Type I, Class 1.

Aircraft Compatibility

• Universal Aerospace Application: This is a standard mil-spec component used in the manufacturing and maintenance of virtually all modern certified and military aircraft, including those from:

  • Textron Aviation, Boeing, Airbus, Lockheed Martin, Bombardier, Gulfstream, Piper, and others.

Applications

• Airframe Wiring Harnesses: Ideal for splicing wires in areas exposed to the elements, such as wheel wells, wing roots, pylons, and bilge areas.

• Engine Compartments: The high-temperature rating makes it suitable for wiring repairs in and around the engine nacelle and firewall.

• Avionics & Sensor Wiring: Provides a highly reliable connection for critical sensor and data lines where signal integrity and environmental protection are paramount.

• High-Vibration Areas: The superior strain relief makes it the preferred splice for any wiring subjected to high levels of vibration.

Why Choose D-436-26?

An intermittent or failed electrical connection in flight can be catastrophic. The TE Connectivity D-436-26 is an engineered system designed to eliminate the common failure modes of simple butt splices. Where an unsealed crimp is vulnerable to moisture intrusion, corrosion, and vibration-induced fatigue, the MiniSeal® splice creates a fully encapsulated, strain-relieved, and corrosion-proof joint. Its reliability is proven and backed by the most stringent military and aerospace standards. For any splice in a location exposed to moisture, fluids, or vibration, there is no substitute for the certified, sealed protection of a Raychem MiniSeal®.

The engineering principle that provides the D-436-26 its unparalleled reliability is the creation of a synergistic, multi-functional seal. The installation process involves two distinct but simultaneous actions. First, a calibrated crimp tool creates a metallurgically sound, cold-weld connection. Second, a controlled heat source (a heat gun with a reflector) is applied. This heat performs two functions: 1) It shrinks the radiation-crosslinked PVDF sleeve. The cross-linking process creates a polymer with a "memory," causing it to shrink with immense force, providing a rigid, protective outer shell. 2) Simultaneously, the heat melts the colored thermoplastic sealing inserts at each end. These inserts are low-viscosity polymers that flow into the microscopic voids between the wire strands and the wire's insulation, creating a complete adhesive bond. Upon cooling, this forms a solid, impenetrable plug that makes the splice waterproof and provides robust strain relief by bonding the sleeve directly to the wire insulation, effectively isolating the mechanical crimp from any external stress.

Note: The D-436-26 is a flight-critical electrical component. It must be installed using a properly calibrated mil-spec crimping tool (per SAE-AS22520, such as the M22520/37-01 with the correct die set) and a controlled-temperature heat gun. Using incorrect tools, pliers, or an open flame will result in an un-airworthy connection and is strictly prohibited. The wires must be stripped to the correct length, and the crimp must be visually inspected through the transparent sleeve after installation.

Documentation

• SAE-AS81824/1: The Aerospace Standard document defines all dimensional, material, and performance requirements for this splice and is available through SAE International and other standards providers.

• TE Connectivity Website: The manufacturer's datasheet with detailed performance characteristics is available on the TE Connectivity website.